Vacuum cleaner

ABSTRACT

A vacuum cleaner includes a suction inlet, a suction source configured to generate an airflow through the suction inlet to draw debris with the airflow through the suction inlet, and a separator assembly. The separator assembly includes a housing having an air inlet and an air outlet, a debris collection chamber within the housing, and an inner chamber formed within a shroud that defines a cyclone axis and has a perforated portion. The inner chamber has a first end and a second end. The first end has a tangential inlet. The second end is open toward the debris collection chamber. An outflow passageway is outside of the shroud and in fluid communication with the air outlet and a filter is in fluid communication with the outflow passageway.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/531,823, filed on Aug. 5, 2019, which issued as U.S. Pat. No.10,959,587 on Mar. 30, 2021, which claims priority to U.S. ProvisionalPatent Application No. 62/714,857, filed on Aug. 6, 2018, the entirecontent all of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to vacuum cleaners, and more particularlyto vacuum cleaners with separator assemblies.

BACKGROUND OF THE INVENTION

Vacuum cleaners use separator assemblies to separate large dust anddebris from the airflow that is suctioned into the vacuum cleaner.

SUMMARY OF THE INVENTION

In one embodiment, a vacuum cleaner includes a suction inlet, a suctionsource configured to generate an airflow through the suction inlet todraw debris with the airflow through the suction inlet, and a separatorassembly downstream from the suction inlet for separating debris fromthe airflow. The separator assembly includes a housing having an airinlet and an air outlet, a debris collection chamber within the housing,and an inner chamber formed within a shroud that defines a cyclone axisand has a perforated portion. The inner chamber has a first end and asecond end. The first end has a tangential inlet. The second end is opentoward the debris collection chamber. The separator assembly alsoincludes an outflow passageway outside of the shroud and in fluidcommunication with the air outlet and a filter in fluid communicationwith the outflow passageway. The first end of the inner chamber ispositioned between the air outlet and the second end of the innerchamber. The tangential inlet is configured to provide airflow anddebris to rotate around the cyclone axis within the inner chamber. Theairflow and debris is configured to move from the first end of the innerchamber toward the second end of the inner chamber unimpeded by anystructure extending transverse to the cyclone axis. The airflow isconfigured to exit the inner chamber and enter the outflow passageway bypassing through the perforated portion of the shroud.

In one embodiment, a vacuum cleaner includes a suction inlet, a suctionsource configured to generate an airflow through the suction inlet todraw debris with the airflow through the suction inlet, and a separatorassembly downstream from the suction inlet for separating debris fromthe airflow. The separator assembly includes a housing having an airinlet and an air outlet, a debris collection chamber within the housing,and an inner chamber formed within a shroud that defines a cyclone axisand has a perforated portion. The inner chamber has a first end and asecond end. The second end is open toward the debris collection chamber.The air inlet is configured to provide the airflow and debris to rotatearound the cyclone axis within the shroud. The separator assembly alsoincludes an outflow passageway outside of the shroud and in fluidcommunication with the air outlet. Air flow is configured to exit theinner chamber and enter the outflow passageway by passing through theperforated portion of the shroud. The separator assembly also includes afilter chamber between the first end of the inner chamber and the airoutlet. The filter chamber defines a longitudinal axis. The separatorassembly also includes a cylindrical filter in the filter chamber. Thecylindrical filter is arranged along the longitudinal axis. The airflowis configured to flow through the cylindrical filter in a directiontransverse to the longitudinal axis.

In one embodiment, a vacuum cleaner includes a suction inlet, a suctionsource configured to generate an airflow through the suction inlet todraw debris with the airflow through the suction inlet, and a separatorassembly downstream from the suction inlet for separating debris fromthe airflow. The separator assembly includes a housing having an airinlet and an air outlet, a debris collection chamber within the housing,and an inner chamber within a shroud that defines a cyclone axis and hasa perforated portion. The inner chamber has a first end and a secondend. The second end is open toward the debris collection chamber. Theair inlet is configured to provide the airflow and debris to rotatearound the cyclone axis within the shroud. The separator assembly alsoincludes an outflow passageway outside of the shroud and in fluidcommunication with the air outlet. The air flow is configured to exitthe inner chamber and enter the outflow passageway by passing throughthe perforated portion of the shroud. The vacuum cleaner also includes aplurality of second stage cyclones. Each second stage cyclone has asecond stage air inlet, a second stage air outlet, and a debris outlet.Each second stage air inlet is in fluid communication with the outflowpassageway. The vacuum cleaner also includes a filter in communicationwith each of the second stage air outlets.

Other features and aspects of the invention will become apparent byconsideration of the following detailed description and accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vacuum cleaner.

FIG. 2 is a cross-sectional view of the vacuum cleaner of FIG. 1 .

FIG. 3 is a partial cross-sectional view of a portion of separatorassembly of the vacuum cleaner of FIG. 1 .

FIG. 4 is a perspective view of another embodiment of a vacuum cleaner.

FIG. 5 is a perspective view of the vacuum cleaner of FIG. 1 with aseparator assembly removed.

FIG. 6 is a perspective view of a separator assembly of the vacuumcleaner of FIG. 5 .

FIG. 7 is a cross-sectional view of the separator assembly of FIG. 6 .

FIG. 8 is a cross-sectional view of the separator assembly of FIG. 6 .

FIG. 9 is a cross-sectional view of another embodiment of a separatorassembly of the vacuum cleaner of FIG. 4 .

FIG. 10 is a cross-sectional view of the separator assembly of FIG. 9 .

FIG. 10A is a cross-sectional view of an alternative embodiment of theseparator assembly of FIG. 9 .

FIG. 11 is a perspective view of another embodiment of a vacuum cleaner.

FIG. 12 is a perspective view of a separator assembly of the vacuumcleaner of FIG. 11 .

FIG. 13 is a cross-sectional view of the separator assembly of FIG. 12 .

FIG. 14 is a cross-sectional view of the separator assembly of FIG. 12 .

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting.

DETAILED DESCRIPTION

FIGS. 1 and 2 illustrate a vacuum cleaner 10. As shown in FIGS. 2 and 3and explained in further detail below, the vacuum cleaner 10 includes aseparator assembly 14 including a separator assembly housing 18 havingan air inlet 22, an air outlet 26, and a debris collection chamber 30within the housing 18. The separator assembly 14 also includes an innerchamber 34 formed within a shroud 38 that defines a cyclone axis 42 andhas a perforated portion 46. The inner chamber 34 has a first end 50 anda second end 54. The first end 50 has a tangential inlet 58 to the innerchamber and the second end 54 of the inner chamber is open toward thedebris collection chamber 30. The debris collection chamber 30 surroundsthe shroud 38 and has an end 60 that is intersected by the cyclone axis42 and spaced from the second end 54 of the inner chamber 34. Theseparator assembly 14 also includes an outflow passageway 62 outside ofthe shroud 38 and in fluid communication with the air outlet 26. Theseparator assembly 14 also includes a filter 66 in fluid communicationwith the outflow passageway 62. The first end 50 of the inner chamber 34is positioned between the air outlet 26 and the second end 54 of theinner chamber 34.

During operation of the vacuum cleaner 10, the tangential inlet 58 isconfigured to provide an airflow and debris to rotate around the cycloneaxis 42 within the inner chamber 34. Once in the inner chamber 34, theairflow and debris move from the first end 50 of the inner chamber 34 tothe second end 54 of the inner chamber 34 unimpeded by any structureextending transverse to the cyclone axis 42. Specifically, within theinner chamber 34 there is no structure extending radially inward fromthe shroud 38 toward the cyclone axis 42 and there is no structureextending radially outward from the cyclone axis 42 toward the shroud38. While a portion of the shroud 38 that secures the perforated portion46 or the perforated portion 46 itself may bulge inward towards thecyclone axis 42 a nominal amount, this does not constitute structureextending transverse to the cyclone axis 42. The airflow exits the innerchamber 34 by passing through the perforated portion 46 of the shroud 38to the outflow passageway 62.

With reference again to FIGS. 1 and 2 , the vacuum cleaner 10 includesan outer housing 68, a suction inlet 70 and a suction source, such assuction motor 74, to generate an airflow through the suction inlet 70 todraw debris with the airflow through the suction inlet 70. As shown inFIG. 2 , the suction inlet 70 is fluidly coupled to the air inlet 22 ofthe separator assembly 14, and the suction motor 74 is fluidly coupledto the air outlet 26 of the separator assembly 14. In one alternative,the suction inlet 70 is fluidly coupled to the suction source and theoutlet of the suction source is coupled to the air inlet 22 of theseparator assembly 14. The vacuum cleaner 10 includes a power source,such as one or more rechargeable batteries 78, to provide power to thesuction motor 74, and a switch 80 to actuate the suction motor 74. Inother embodiments, the vacuum cleaner 10 includes a rechargeable batterypack that is removable from the housing 68. The vacuum cleaner 10 alsoincludes a plurality of exhaust vents 82 on the housing 68 to exhaustthe airflow from the suction motor 74 and out of the housing 68.

With continued reference to FIGS. 2 and 3 , the first end 50 of theinner chamber 34 includes a helical ramp 86 in fluid communication withthe air inlet 22 by a duct 24, the helical ramp 86 extending toward thesecond end 54 of the inner chamber 34 and leading to the tangentialinlet 58. The duct 24 passes through the outflow passageway 62 toconnect the air inlet 22 to the tangential inlet 58 of the inner chamber34. As also shown in FIG. 2 , the separator assembly 14 includes apartition 90 separating the outflow passageway 62 from the debriscollection chamber 30. In the embodiment illustrated in FIG. 2 , thepartition 90 is shaped as a frustrum extending away from the second end54 of the inner chamber 34. In the illustrated embodiment, the partition90 extends away from the second end 54 of the inner chamber 34 such thatthe outflow passageway 62 is bounded by the partition 90 and the shroud38. In another embodiment, the partition 90 extends in a directiontoward the separator assembly housing 18, such that the outflowpassageway 62 is bounded by the separator assembly housing 18 and theshroud 38. Also, in the embodiment illustrated in FIG. 2 , theperforated portion 46 of the shroud 38 is adjacent the second end 54 ofthe inner chamber 34. In some embodiments, the perforated portion 46 ofthe shroud 38 is perforated by a plurality of apertures in a range from0.15 to 0.40 mm in diameter. In other embodiments, the perforatedportion 46 of the shroud 38 is perforated by a plurality of apertures ina range from 0.10 to 0.3 mm in diameter, and may be in the range of 0.10to 0.25 mm in diameter. In some embodiments, the perforated portion 46of the shroud 38 includes an etched perforated metal. Alternatively, theperforated portion 46 may be a stamped sheet, a screen mesh, or otherperforated material. In the embodiment illustrated in FIG. 2 , theshroud 38 includes a non-perforated portion 92 adjacent the first end 50of the inner chamber 34.

As illustrated in the embodiment shown in FIG. 2 , the filter 66 ispositioned in a filter chamber 94 arranged at an upper end 98 of thehousing 18 of the separator assembly 14. As further illustrated in theembodiment shown in FIG. 2 , the filter chamber 94 is arranged betweenthe first end 50 of the inner chamber 34 and the air outlet 26 of theseparator assembly 14. The filter chamber 94 is in fluid communicationwith the outflow passageway 62. In one alternative, the filter 66 is notpositioned in the separator assembly 14 but is mounted in the vacuumcleaner housing 68. In yet another alternative, not shown, a cylindricalfilter is positioned around the shroud 38 in the outflow passageway 62,such that the air flow through the cylindrical filter is transverse tothe cyclone axis 42 to enter the outflow passageway 62.

With reference to FIGS. 1 and 2 , the separator assembly 14 includes afirst latch 102 and a second latch 106. Actuating the first latch 102causes a bottom door 110 at a lower end 112 of the separator assembly 14to pivot open, allowing an operator to empty the debris collected in thedebris collection chamber 30 without removing the separator assembly 14from the housing 68 of the vacuum cleaner 10. The end 60 of the debriscollection is also the lower end 112 of the separator assembly 14 andthe bottom door 110. Actuating the second latch 106 allows an operatorto remove the separator assembly 14 from the housing 68 of the vacuumcleaner 10. In the embodiment illustrated in FIGS. 1-3 , the partition90, the shroud 38, or both are removable from the upper end 98 of thehousing 18 of the separator assembly 14. In one alternative, thepartition 90 is integral with the separator assembly housing 18. Inanother alternative, the partition 90 is integral with the shroud 38. Inyet another embodiment, the partition 90, the shroud 38, or both areremovable from the lower end 112 of the housing 18 of the separatorassembly 14.

In operation, an operator actuates the switch 80 to actuate the suctionmotor 74, which generates an airflow through the suction inlet 70 todraw debris with the airflow through the suction inlet 70. The airflowthen moves from the suction inlet 70 to the air inlet 22 of theseparator assembly 14. From the air inlet 22, the airflow moves alongthe duct 24 to the helical ramp 86 along the upper surface of the airpassageway and enters the inner chamber 34 via the tangential inlet 58,which causes the airflow and debris to rotate around the cyclone axis 42within the inner chamber 34. After entering the inner chamber 34, theairflow and debris move from the first end 50 of the inner chamber 34 tothe second end 54 of the inner chamber 34 unimpeded by any structureextending transverse to the cyclone axis 42. The cyclonic action withininner chamber 34 causes larger debris to drop out of the airflow andinto the debris collection chamber 30, because the second end 54 of theinner chamber 34 is open to the debris collection chamber 30. Meanwhile,the airflow exits the inner chamber 34 and enters the outflow passageway62 by passing through the perforated portion 46 of the shroud 38. Theairflow then moves through the outflow passageway 62 and into the filterchamber 94, where additional debris that passed through the perforatedportion is filtered out of the airflow by the filter 66. The airflowthen passes into the air outlet 26 and through suction motor 74 beforeit is exhausted out exhaust vents 84.

Another embodiment of a vacuum cleaner 116 is shown in FIGS. 4 and 5 .The vacuum cleaner 116 includes a housing 120 and a suction inlet 124leading to a first conduit 128 that transitions the airflow into aseparator assembly 132. The vacuum cleaner 116 includes a suction motor(not shown) and a second conduit 136 (FIG. 5 ) leading to the suctionmotor from the separator assembly 132.

As shown in FIGS. 6 and 7 , the separator assembly 132 includes ahousing 140 having a handle 142, an air inlet 144, an air outlet 148,and a debris collection chamber 152 within the housing 140. When theseparator assembly 132 is mounted on vacuum cleaner 116, the air inlet144 is fluidly coupled with the first conduit 128 and the air outlet 148is fluidly coupled with the second conduit 136. The separator assembly132 also includes an inner chamber 156 formed within a shroud 160 thatdefines a cyclone axis 164. The shroud has a perforated portion 168 anda non-perforated portion 170. The inner chamber 156 has a first end 172and a second end 176. The non-perforated portion 170 of the shroud isadjacent the first end 172 of the inner chamber 156.

In the embodiment illustrated by FIG. 7 , the air inlet 144 is alignedwith and is directly connected to a tangential inlet 180 leading to theinner chamber 156 at the first end 172, and the second end 176 of theinner chamber 156 is open toward the debris collection chamber 152. Inone embodiment, not shown, the first end 172 of the inner chamber 156includes a helical ramp in fluid communication with the air inlet 144and the tangential inlet 180. The separator assembly 132 also includesan outflow passageway 184 outside of the shroud 160 and in fluidcommunication with the air outlet 148. The separator assembly 132 alsoincludes a plurality of second stage cyclones 204 in fluid communicationwith the outflow passageway 184, as described in further detail below.The first end 172 of the inner chamber 156 is positioned between the airoutlet 148 and the second end 176 of the inner chamber 156 in agenerally vertical arrangement. The tangential inlet 180 provides anairflow and debris to rotate around the cyclone axis 164 within theinner chamber 156. Once in the inner chamber 156, the airflow and debrismove from the first end 172 of the inner chamber 156 to the second end176 of the inner chamber 156 unimpeded by any structure extendingtransverse to the cyclone axis 164. The airflow exits the inner chamber156 by passing through the perforated portion 168 of the shroud 160.

The vacuum cleaner 116 can be powered by AC power or a DC power source,such as one or more rechargeable batteries, to provide power to thesuction motor. The vacuum cleaner 10 also includes a plurality ofexhaust vents 192 on the housing 140 to exhaust the airflow from thesuction motor and out of the housing 140.

As shown in FIG. 7 , the separator assembly 132 includes a partition 196separating the outflow passageway 184 from the debris collection chamber152. In the embodiment illustrated in FIG. 7 , the partition 196 extendsaway from the second end 176 of the inner chamber 156 in a directionthat is perpendicular to the cyclone axis 164. In one alternative, notshown, the partition 196 extends at an oblique angle to the cyclone axis164. Also, in the embodiment illustrated in FIG. 7 , the perforatedportion 168 of the shroud 160 is adjacent the second end 176 of theinner chamber 156. In some embodiments, the perforated portion 168 ofthe shroud 160 is perforated by a plurality of apertures in a range from0.15 to 0.40 mm in diameter. In other embodiments, the perforatedportion 168 of the shroud 160 is perforated by a plurality of aperturesin a range from 0.10 to 0.3 mm in diameter, and may be in the range of0.10 to 0.25 mm in diameter. In some embodiments, the perforated portion168 of the shroud 160 includes an etched perforated metal.Alternatively, the perforated portion 168 may be a stamped sheet, ascreen mesh, or other perforated material.

With reference to FIGS. 7 and 8 , the outflow passageway 184 is in fluidcommunication with to the plurality of second stage cyclones 204. Eachof the second stage cyclones 204 includes a tangential second stage airinlet 208, a second stage air outlet 212, and second stage debris outlet216. Each of the second stage debris outlets 216 leads to a second stagedust chamber 220. Each of the second stage air outlets 212 is in fluidcommunication with a filter chamber 224 in which a filter 188 isarranged between the second stage air outlets 212 and the air outlet148. The filter chamber 224 is arranged at an upper end 226 of thehousing 140 of the separator assembly. In one alternative, the filter188 is not positioned in the separator assembly 132 but is mounted inthe vacuum cleaner housing 120. In yet another alternative, not shown, acylindrical filter is positioned around the shroud 160 in the outflowpassageway 184, such that the air flow through the cylindrical filter istransverse to the cyclone axis 164 to enter the outflow passageway 184.As shown in FIG. 7 , the plurality of second stage cyclones 204 arepositioned adjacent the inner chamber 156, and are arranged around theshroud 160 in at least a partially concentric arrangement.

With reference to FIGS. 6 and 7 , the separator assembly 132 includes abottom door 232 at a lower end 236 of the separator assembly 132openable by a latch 228, allowing an operator to empty the debriscollected in the debris collection chamber 152 after the separatorassembly 132 has been removed from the vacuum cleaner 116. In theembodiment illustrated in FIG. 7 , the second stage dust chamber 220 isclosed by a removable cover 222. In some embodiments, the second stagedust chamber 220 is openable with the bottom door 232. In the embodimentillustrated in FIGS. 6-7 , the partition 196, the shroud 160, or bothare removable from the upper end 226 of the separator assembly 132.

In operation, while the separator assembly 132 is mounted to the vacuumcleaner 116, an operator actuates the suction motor of the vacuumcleaner 116, which generates an airflow through the suction inlet 124 todraw debris with the airflow through the suction inlet 124. The airflowthen moves from the suction inlet 124 through the first conduit 128 tothe air inlet 144 of the separator assembly 132. From the air inlet 144,the airflow enters the inner chamber 156 via the tangential inlet 180,which provides the airflow and debris to rotate around the cyclone axis164 within the inner chamber 156. Once in the inner chamber 156, theairflow and debris move from the first end 172 of the inner chamber 156to the second end 176 of the inner chamber 156 unimpeded by anystructure extending transverse to the cyclone axis 164. The cyclonicaction within inner chamber 156 causes larger debris to drop out of theairflow and into the debris collection chamber 152, because the secondend 176 of the inner chamber 156 is open to the debris collectionchamber 152.

The airflow exits the inner chamber 156 and enters the outflowpassageway 184 by passing through the perforated portion 168 of theshroud 160. The airflow then moves through the outflow passageway 184and into each of the second stage cyclones 204 via each of thetangential second stage air inlets 208. The cyclonic action within eachsecond stage cyclone 204 causes debris that passed through theperforated portion 168 to drop out of the airflow, through the secondstage debris outlets 216 and into the second stage dust chamber 220. Theairflow exits out of each second stage cyclone 204 via the second stageair outlet 212, where the airflow enters the filter chamber 224. Theairflow is further filtered by filter 188 in filter chamber 224, beforeit is drawn out of the air outlet 148 and into the second conduit 136 ofthe vacuum cleaner 116. The second conduit 136 fluidly communicates theairflow to the suction motor, after which it is exhausted out of thevacuum cleaner 116 via the exhaust vents 192.

FIGS. 9 and 10 illustrate another embodiment of a separator assembly 240for the vacuum cleaner 116. As shown in FIGS. 9 and 10 , the separatorassembly 240 includes a housing 244 having a handle 246, an air inlet248, an air outlet 250, and a debris collection chamber 252 within thehousing 244. When the separator assembly 240 is mounted on the vacuumcleaner 116, the air inlet 248 is fluidly coupled with the first conduit128 and the air outlet 250 is fluidly coupled with the second conduit136. The separator assembly 240 also includes an inner chamber 256formed within a shroud 260 that defines a cyclone axis 264. The shroud260 has a perforated portion 268 and a non-perforated portion 270. Theinner chamber 256 has a first end 272 and a second end 276. Thenon-perforated portion 270 is adjacent the first end 272 of the innerchamber 256.

In the embodiment illustrated by FIG. 9 , the air inlet 248 is connectedto a duct 242 in communication with a tangential inlet 280 to the innerchamber 256 at the first end 272, and the second end 276 is open towardthe debris collection chamber 252. In one embodiment, not shown, thefirst end 272 of the inner chamber 256 includes a helical ramp in fluidcommunication with the duct 242 and the tangential inlet 280. Theseparator assembly 240 also includes an outflow passageway 284 outsideof the shroud 260 and in fluid communication with the air outlet 250.The separator assembly 240 also includes a filter 288 in fluidcommunication with the outflow passageway 284. The filter 288 is acylindrical filter arranged along a longitudinal axis 292 defined by afilter chamber 296, in which the filter 288 is arranged. In theillustrated embodiment, the filter chamber 296 is positioned between thefirst end 272 of the inner chamber 256 and the air outlet 250. Withreference to FIGS. 9 and 10 , the outflow passageway 184 includes aplurality of swirl vanes 308 configured to generate a swirl orrotational flow in the filter chamber 296 around the longitudinal axis292 and the filter 288. In the embodiment illustrated in FIG. 9 , thelongitudinal axis 292 is coaxial with the cyclone axis 264, but in otherembodiments, the longitudinal axis 292 is parallel but not coaxial withthe cyclone axis 264. The filter 288 surrounds a filter outletpassageway 300 that is fluidly coupled to the air outlet 250.

With continued reference to FIGS. 9 and 10 , the first end 272 of theinner chamber 256 is positioned between the air outlet 250 and thesecond end 276 of the inner chamber 256. The first end 272 is alsopositioned between the filter chamber 296 and the second end 276 in agenerally vertical arrangement. The duct 242 passes through the outflowpassageway 284 to connect the air inlet 248 to the tangential inlet 280of the inner chamber 256. Airflow and debris enter the inner chamber 256along the tangential inlet 280, which provides the airflow and debris torotate around the cyclone axis 264 within the inner chamber 256. Once inthe inner chamber 256, the airflow and debris move from the first end272 of the inner chamber 256 to the second end 276 of the inner chamber256 unimpeded by any structure extending transverse to the cyclone axis264. The airflow exits the inner chamber 256 by passing through theperforated portion 268 of the shroud 260 into the outflow passageway284. From the outflow passageway 284, the airflow passes through theswirl vanes 308 to the filter chamber 296.

With continued reference to FIGS. 9 and 10 , the separator assembly 240includes a partition 304 separating the outflow passageway 284 from thedebris collection chamber 252. In the embodiment illustrated in FIGS. 9and 10 , the partition 304 extends away from the second end 276 of theinner chamber 256 in a direction that is perpendicular to the cycloneaxis 264. In one alternative, the partition 304 extends at an obliqueangle to the cyclone axis 264. Also, in the embodiment illustrated inFIGS. 9 and 10 , the perforated portion 268 of the shroud 260 isadjacent the second end 276 of the inner chamber 256. In someembodiments, the perforated portion 268 of the shroud 260 is perforatedby a plurality of apertures in a range from 0.15 to 0.40 mm in diameter.In other embodiments, the perforated portion 268 of the shroud 260 isperforated by a plurality of apertures in a range from 0.10 to 0.3 mm indiameter, and may be in the range of 0.10 to 0.25 mm in diameter. Insome embodiments, the perforated portion 268 of the shroud 260 includesan etched perforated metal. Alternatively, the perforated portion 268may be a stamped sheet, a screen mesh, or other perforated material.

In one embodiment shown in FIG. 10A, a cylindrical filter 298 ispositioned around the shroud 260 in the outflow passageway 284. In thisembodiment, airflow passing through the perforated shroud 268 enters andpasses through the cylindrical filter 298 in a direction that istransverse to the cyclone axis to enter the outflow passageway 284.

With reference to FIG. 10 , the separator assembly 240 includes a bottomdoor 318 at a lower end 322 of the separator assembly 240 openable by alatch 314, allowing an operator to empty the debris collected in thedebris collection chamber 252 after the separator assembly 240 has beenremoved from the vacuum cleaner 116.

In operation, when the separator assembly 240 of FIGS. 9 and 10 ismounted to the vacuum cleaner of FIGS. 4 and 5 , an operator actuatesthe suction motor of the vacuum cleaner 116, which generates an airflowthrough the suction inlet 124 to draw debris with the airflow throughthe suction inlet 124. The airflow then moves from the suction inlet 124through the first conduit 128 to the air inlet 248 of the separatorassembly 240. From the air inlet 248, the airflow enters the innerchamber 256 via the duct 242 and tangential inlet 280, which causes theairflow and debris to rotate around the cyclone axis 264 within theinner chamber 256. After entering the inner chamber 256, the airflow anddebris move from the first end 272 of the inner chamber 256 to thesecond end 276 of the inner chamber 256 unimpeded by any structureextending transverse to the cyclone axis 264. The cyclonic action withininner chamber 256 causes larger debris to drop out of the airflow andinto the debris collection chamber 252, because the second end 276 ofthe inner chamber 256 is open to the debris collection chamber 252.

The airflow exits the inner chamber 256 and enters the outflowpassageway 284 by passing through the perforated portion 268 of theshroud 260. The airflow then moves through the outflow passageway 284and through the swirl vanes 308, causing the airflow to be swirledaround the filter 288 within the filter chamber 296. The airflow thenflows through the filter 288 in a direction transverse to thelongitudinal axis 292 of the filter chamber 296, causing moreparticulate matter to be filtered out. The airflow then flows throughthe passageway 300 to the air outlet 250, where it is then drawn intothe second conduit 136 of the vacuum cleaner 116. The second conduit 136fluidly communicates the airflow to the suction motor, after which it isexhausted out of the vacuum cleaner 116 via the exhaust vents 192.

FIG. 11 illustrates another embodiment of a vacuum cleaner 326. As shownin FIGS. 11-14 and explained in further detail below, the vacuum cleaner326 includes a separator assembly 330 including a separator assemblyhousing 334 having an air inlet 338, an air outlet 342, and a debriscollection chamber 346 within the housing 334. The separator assembly330 also includes an inner chamber 350 formed within a shroud 354 thatdefines a cyclone axis 358. The shroud 354 has a perforated portion 360and a non-perforated portion 362. The inner chamber 350 has a first end366 and a second end 370. The non-perforated portion 362 is arrangedadjacent the first end 366 of the inner chamber 350.

The first end 366 has a helical ramp 372 in fluid communication with theair inlet 338 by a duct 376 shown in FIG. 13 , the helical ramp 372leading to a tangential inlet 374 to the inner chamber, and the secondend 370 of the inner chamber 350 is open toward the debris collectionchamber 346. The separator assembly 330 also includes an outflowpassageway 378 outside of the shroud 354 and in fluid communication withthe air outlet 342. The separator assembly 330 also includes a filter382 in fluid communication with the outflow passageway 378. The firstend 366 of the inner chamber 350 is positioned between the air outlet342 and the second end 370 of the inner chamber 350. The duct 376 passesthrough the outflow passageway 378 to connect the air inlet 338 to theinner chamber 350. Airflow and debris enter the inner chamber 350 alongthe tangential inlet 374, which causes an airflow and debris to rotatearound the cyclone axis 358 within the inner chamber 350. Once in theinner chamber 350, the airflow and debris move from the first end 366 ofthe inner chamber 350 to the second end 370 of the inner chamber 350unimpeded by any structure extending transverse to the cyclone axis 358.The airflow exits the inner chamber 350 by passing through theperforated portion 360 of the shroud 354 into the outflow passageway378.

With reference again to FIG. 11 , the vacuum cleaner 326 includes anouter housing 386, a suction inlet 390 and a suction source, such as asuction motor (not shown), to generate an airflow through the suctioninlet 390 to draw debris with the airflow through the suction inlet 390.When the separator assembly 330 is mounted to the vacuum cleaner 326,the suction inlet 390 is fluidly coupled to the air inlet 338 of theseparator assembly 330, and the suction motor is fluidly coupled to theair outlet 342 of the separator assembly 330. The vacuum cleaner 326includes a power source, such as one or more rechargeable batteries, toprovide power to the suction motor, and a switch to actuate the suctionmotor. The vacuum cleaner 326 also includes a plurality of exhaust vents394 on the housing 386 to exhaust the airflow from the suction motor andout of the housing 386. The vacuum cleaner 326 also includes a latch 396to release a hook 398 of the separator assembly 330, thereby allowing anoperator to remove the separator assembly 330 from the vacuum cleaner326.

With continued reference to FIG. 14 , the separator assembly 330includes a partition 400 separating the outflow passageway 378 from thedebris collection chamber 346. In the embodiment illustrated in FIG. 14, the partition 400 extends away from the second end 370 of the innerchamber 350 in a direction that is perpendicular to the cyclone axis 358such that the outflow passageway 378 is bounded by the separatorassembly housing 334 and the shroud 354. In one alternative, thepartition 400 extends at an angle to the cyclone axis 358. Also, in theembodiment illustrated in FIG. 14 , the perforated portion 360 of theshroud 354 is adjacent the second end 370 of the inner chamber 350. Insome embodiments, the perforated portion 360 of the shroud 354 isperforated by a plurality of apertures in a range from 0.15 to 0.40 mmin diameter. In other embodiments, the perforated portion 360 of theshroud 354 is perforated by a plurality of apertures in a range from0.10 to 0.3 mm in diameter, and may be in the range of 0.10 to 0.25 mmin diameter. In some embodiments, the perforated portion 360 of theshroud 354 includes an etched perforated metal. Alternatively, theperforated portion 360 may be a stamped sheet, a screen mesh, or otherperforated material.

As illustrated in the embodiment shown in FIG. 14 , the filter 382 ispositioned in a filter chamber 402 arranged at an upper end 406 of thehousing 334 of the separator assembly 330. As further illustrated in theembodiment shown in FIG. 14 , the filter chamber 402 is arranged betweenthe first end 366 of the inner chamber 350 and the air outlet 342 of theseparator assembly 330. Also in the illustrated embodiment, the shroud354 includes standoffs or tabs 407 that properly position the filter 382in the separator assembly 330. The filter 382 contacts the tabs 407 tostop movement of the filter 382 toward a lower end 418 of the separatorassembly 330. Therefore, the user cannot insert the filter 382 too fartoward the lower end 418 and the filter 382 is held in position and alsothe filter 382 is not drawn toward the lower end 418 by the suctionairflow. The tabs 407 are coupled to the shroud 354 so that the tabs 407are removable with the shroud 354 from the housing 334. The filterchamber 402 is in fluid communication with the outflow passageway 378.In one alternative, the filter 382 is not positioned in the separatorassembly 330 but is mounted in the vacuum cleaner housing 383. In yetanother alternative, not shown, a cylindrical filter is positionedaround the shroud 354 in the outflow passageway 378, such that the airflow through the cylindrical filter is transverse to the cyclone axis358 to enter the outflow passageway 378.

With reference to FIGS. 12 and 14 , the separator assembly 330 includesa latch 410, whose actuation causes a door 414 at the lower end 418 ofthe separator assembly 330 to pivot open, allowing an operator to emptythe debris collected in the debris collection chamber 346 withoutremoving the separator assembly 330 from the housing 68 of the vacuumcleaner 326. In the embodiment illustrated in FIGS. 12-14 , thepartition 400 is integral with the shroud 354 and both are removablefrom the upper end 406 of the housing 334 of the separator assembly 330.Alternatively, the partition 400 is integral with the separator assemblyhousing 334. In another alternative, the partition 400, the shroud 354,or both are removable from the upper end 406 or lower end 418 of thehousing 334 of the separator assembly 330 as desired.

In operation of vacuum cleaner 326, an operator actuate the switch toactuate the suction motor, which generates an airflow through thesuction inlet 390 to draw debris with the airflow through the suctioninlet 390. The airflow then moves from the suction inlet 390 to the airinlet 338 of the separator assembly 330. From the air inlet 338, theairflow passes through the duct 376 and enters the inner chamber 350 viathe helical ramp 372 and the tangential inlet 374, which provides theairflow and debris to rotate around the cyclone axis 358 within theinner chamber 350. After entering the inner chamber 350, the airflow anddebris move from the first end 366 of the inner chamber 350 to thesecond end 370 of the inner chamber 350 unimpeded by any structureextending transverse to the cyclone axis 358. The cyclonic action withininner chamber 350 causes larger debris to drop out of the airflow andinto the debris collection chamber 346, because the second end 370 ofthe inner chamber 350 is open to the debris collection chamber 346.

Meanwhile, the airflow exits the inner chamber 350 and enters theoutflow passageway 378 by passing through the perforated portion 360 ofthe shroud 354. The airflow then moves through the outflow passageway378 and into the filter chamber 402, where additional debris that passedthrough the perforated portion 360 is filtered out of the airflow by thefilter 382. The airflow then passes into the air outlet 342 and throughthe suction motor before it is exhausted out of exhaust vents 394 on thehousing 386 of vacuum cleaner 326.

Various features of the invention are set forth in the following claims.

What is claimed is:
 1. A vacuum cleaner comprising: a suction inlet; asuction source configured to generate an airflow through the suctioninlet to draw debris with the airflow through the suction inlet; and aseparator assembly downstream from the suction inlet for separatingdebris from the airflow, the separator assembly including: a housinghaving an air inlet and an air outlet, a debris collection chamberwithin the housing, an inner chamber formed within a shroud that definesa cyclone axis and has a perforated portion, the inner chamber having afirst end and a second end, the first end having a tangential inlet, thesecond end being open toward the debris collection chamber, and anoutflow passageway outside of the shroud and in fluid communication withthe air outlet, wherein the tangential inlet is configured to provideairflow and debris to rotate around the cyclone axis within the innerchamber, wherein the airflow and debris is configured to move from thefirst end of the inner chamber toward the second end of the innerchamber unimpeded by any structure extending transverse to the cycloneaxis, and wherein the airflow is configured to exit the inner chamberand enter the outflow passageway by passing through the perforatedportion of the shroud.
 2. The vacuum cleaner of claim 1, furthercomprising a partition separating the outflow passageway from the debriscollection chamber.
 3. The vacuum cleaner of claim 2, wherein thehousing has an upper end and a lower end, and wherein the partition, theshroud, or both are removable from the upper end.
 4. The vacuum cleanerof claim 3, wherein the partition extends away from the second end ofthe inner chamber in a direction that is perpendicular to the cycloneaxis.
 5. The vacuum cleaner of claim 2, where the partition is shaped asa frustum extending away from the second end of the inner chamber. 6.The vacuum cleaner of claim 1, wherein the shroud includes anon-perforated portion adjacent the first end.
 7. The vacuum cleaner ofclaim 1, wherein the perforated portion of the shroud is perforated by aplurality of apertures in a range from 0.10 to 0.40 mm in diameter. 8.The vacuum cleaner of claim 7, wherein the perforated portion of theshroud includes an etched perforated metal.
 9. The vacuum cleaner ofclaim 1, wherein the first end includes a helical ramp extending towardthe second end of the inner chamber.
 10. The vacuum cleaner of claim 1,wherein the perforated portion of the shroud is adjacent the second endof the inner chamber.
 11. The vacuum cleaner of claim 1, wherein thedebris collection chamber at least partially surrounds the shroud. 12.The vacuum cleaner of claim 1, wherein the debris collection chamber hasan end that is intersected by the cyclone axis and spaced from thesecond end of the inner chamber.
 13. The vacuum cleaner of claim 12,wherein the end of the debris collection chamber is an end of theseparator assembly.
 14. The vacuum cleaner of claim 12, wherein the endof the debris collection chamber is a door, the door openable to emptythe debris collected in the debris collection chamber.
 15. The vacuumcleaner of claim 1, wherein the first end of the inner chamber ispositioned between the air outlet and the second end of the innerchamber.
 16. A vacuum cleaner comprising: a suction inlet; a suctionsource configured to generate an airflow through the suction inlet todraw debris with the airflow through the suction inlet; and a separatorassembly downstream from the suction inlet for separating debris fromthe airflow, the separator assembly including: a housing having an airinlet and an air outlet, a debris collection chamber within the housing,an inner chamber within a shroud that defines a cyclone axis and has aperforated portion, the inner chamber having a first end and a secondend, the second end being open toward the debris collection chamber,wherein the air inlet is configured to provide the airflow and debris torotate around the cyclone axis within the shroud, an outflow passagewayoutside of the shroud and in fluid communication with the air outlet,wherein the air flow is configured to exit the inner chamber and enterthe outflow passageway by passing through the perforated portion of theshroud, and a plurality of second stage cyclones, each having a secondstage air inlet, a second stage air outlet, and a debris outlet, eachsecond stage air inlet being in fluid communication with the outflowpassageway.
 17. The vacuum cleaner of claim 16, wherein the plurality ofsecond stage cyclones are positioned adjacent the inner chamber.
 18. Thevacuum cleaner of claim 16, wherein the plurality of second stagecyclones are arranged around the shroud at least partially concentric tothe shroud.
 19. The vacuum cleaner of claim 16, wherein the housing hasan upper end and a lower end, where the lower end is openable, andwherein the second stage cyclone debris outlets discharge into a secondstage dust chamber that is openable with the lower end.
 20. The vacuumcleaner of claim 16, wherein the perforated portion of the shroud isadjacent the second end of the inner chamber.